ME-RC Remote - Installation and Operation Guide

ME-RC Remote Control

Inverting DC: 12.6V

50A

Owner’s Manual (for Revision 2.5 or higher)

Disclaimer of Liability Since the use of this manual and the conditions or methods of installation, operation, use and maintenance of the ME-RC are beyond the control of Magnum Energy Inc., this company does not assume responsibility and expressly disclaims liability for loss, damage or expense, whether direct, indirect, consequential or incidental, arising out of or anyway connected with such installation, operation, use, or maintenance. Due to continuous improvements and product updates, the images shown in this manual may not exactly match the unit purchased.

Restrictions on Use The ME-RC remote shall not be used in connection with life support systems, life saving or other medical equipment or devices. Using the ME-RC with this particular equipment is at your own risk.

Important Product Safety Instructions This manual contains important safety instructions that must be followed during the installation and operation of this product. Read all instructions and safety information contained in this manual before installing or using this product. • All electrical work must be performed in accordance with local, state and federal electrical codes. • This product is designed for indoor / compartment installation. It must not be exposed to rain, snow, moisture or liquids of any type. • Use insulated tools to reduce the chance of electrical shock or accidental short circuits. • Remove all jewelry such as rings, watches, bracelets, etc., when installing or performing maintenance on the inverter. • Always disconnect the batteries or energy source prior to installing or performing maintenance on the inverter. Live power may be present at more than one point since an inverter utilizes both batteries and AC. Turning off the inverter may not reduce this risk. As long as AC power is connected, it will pass thru the inverter regardless of the power switch on the inverter or the ON/OFF INVERTER pushbutton on the remote. Safety Symbols To reduce the risk of electrical shock, fire, or other safety hazard, the following safety symbols have been placed throughout this manual to indicate dangerous and important safety instructions. WARNING: This symbol indicates that failure to take a specified action could result in physical harm to the user. CAUTION: This symbol indicates that failure to take a specified action could result in damage to the equipment. Info: This symbol indicates information that emphasizes or supplements important points of the main text. Remedy: This symbol provides possible solutions for related issues.

List of Contents 1.0 Overview..................................................................................... 1 2.0 Installation................................................................................... 2 2.1 Installation Guidelines................................................................. 2 2.2 Tools Required............................................................................ 2 2.3 Installation Procedure.................................................................. 2 3.0 Setup.......................................................................................... 4 3.1 Navigating the Remote’s Menu...................................................... 4 3.2 Menu Pushbuttons and Menu Items............................................... 6 3.2.1 SHORE Menu......................................................................... 6 3.2.2 AGS Menu............................................................................. 7 3.2.3 METER Menu.......................................................................... 7 3.2.4 SETUP Menu.......................................................................... 8 3.2.5 TECH Menu.......................................................................... 16 4.0 Menu Map: ME-RC Remote Control................................................ 18 5.0 Operation................................................................................... 20 5.1 Front Panel............................................................................... 20 5.1.1 LED Indicators..................................................................... 20 5.1.2 LCD Display......................................................................... 20 5.1.3 ON/OFF Pushbuttons............................................................. 21 5.1.4 Menu Pushbuttons................................................................ 21 5.1.5 Rotary SELECT Knob............................................................. 21 5.2 Operating the Inverter/Charger................................................... 22 5.2.1 Inverter Mode...................................................................... 22 5.2.2 Charger mode...................................................................... 22 5.3 System Status Messages............................................................ 23 5.3.1 Inverter Mode Messages........................................................ 23 5.3.2 Charger Mode Messages........................................................ 24 5.3.3 Fault Mode Messages............................................................ 27 5.3.4 LED Indicator Guide.............................................................. 34 6.0 Troubleshooting ......................................................................... 35 6.1 Troubleshooting Tips - .............................................................. 36 6.1.1 Inverter problems:............................................................... 36 6.1.2 Charger problems:............................................................... 36 6.2 Performing an Inverter Reset...................................................... 37 6.3 Powering-down the Inverter....................................................... 37 7.0 Limited Warranty........................................................................ 38 Tables Table Table Table Table Table Table

3-1, 3-2, 3-3, 3-4, 5-1, 6-1,

Battery AmpHrs to Absorb Charging Time............................. 10 Battery Size to Battery Amp-hours (estimated)...................... 11 Battery Type to Charge Voltages.......................................... 12 Inverter/Charger Default Settings........................................ 17 LED Indicator Guide........................................................... 34 Remote Control Troubleshooting Guide................................. 35

©2009 Magnum Energy Inc.

List of Figures Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure

ii

1-1, Front Panel Features........................................................... 1 2-1, Remote Cut-Out Dimensions................................................ 3 2-2, Remote Control Connections................................................ 3 3-1, Front Panel Set-up Features................................................. 4 3-2, SETUP Menu Navigation ..................................................... 5 3-3, SHORE: Shore Max Selections.............................................. 6 3-4, AGS Menu Display.............................................................. 7 3-5, METER: 01 INV/CHG Meter Display....................................... 7 3-6 thru 3-13, SETUP Menu Selections.................................... 8-15 3-14 thru 3-18, TECH Menu Displays/Selection...................... 16-17 4-1, Inverter/Charger Menu Map............................................... 18 5-1, ME-RC Front Panel Controls and Indicators.......................... 20 5-2, Off Mode......................................................................... 23 5-3, Searching Mode............................................................... 23 5-4, Inverting Mode................................................................ 23 5-5, Charging Mode................................................................. 24 5-6, Bulk Charging Mode.......................................................... 24 5-7, Absorb Charging Mode...................................................... 24 5-8, Float Charging Mode......................................................... 25 5-9, Full Charge Mode............................................................. 25 5-10, Charger Standby Mode.................................................... 25 5-11, Equalizing Mode............................................................. 26 5-12, Low Battery Fault........................................................... 27 5-13, High Battery Fault.......................................................... 27 5-14, Overtemp Fault.............................................................. 28 5-15, AC Overload Fault........................................................... 28 5-16, High Volts AC Fault......................................................... 28 5-17, Dead Battery Charge Fault............................................... 29 5-18, Overcurrent Fault........................................................... 29 5-19, FET Overload Fault......................................................... 30 5-20, Breaker Tripped Fault...................................................... 30 5-21, Unknown Fault............................................................... 30 5-22, Tfmr Overtemp Fault....................................................... 31 5-23, Fatal Error $ Fault........................................................... 31 5-24, No Inverter Comm.......................................................... 31 5-25, StackClock Fault............................................................. 32 5-26, Stack Mode Fault............................................................ 32 5-27, StackPhase Fault............................................................ 32 5-28, Internal Bridge Fault....................................................... 33 5-29 Internal Charger Fault...................................................... 33 5-30, Internal NTC Fault.......................................................... 33 5-31, Internal Relay Fault........................................................ 33 6-1, Performing an Inverter Reset............................................. 37


1.0 Overview 1.0 Overview The ME-RC remote control allows you to monitor and customize the operating parameters to your Magnum inverter/charger. It is the same remote used on all Magnum inverter/charger models in the ME, MM, MS, and the RD Series lines so there is no cross-platform confusion. The ME-RC50 comes standard with a 50 foot, 4-conductor (twisted-pair) telephone cable and includes non-volatile memory (preserves adjustable settings, even if power to the remote or inverter is removed). The Magnum remote control has all of the programming and operation functions included in an easy-to-use package. This manual is for the ME-RC with revision 2.5 or higher; see the TECH: 02 Revisions display on page 16 for information on how to determine your revision level.

Inverting DC: 12.6V

50A

Figure 1-1, Front Panel Features The ME-RC is equipped with the following features: • LED Indicators - The at-a-glance LEDs provide the inverter/charger status in a straightforward way. • LCD Display - The LCD display is a 16 x 2 line (32 characters total), alphanumeric display, used for setting up the inverter/charger operation as well as viewing current status or fault messages. • ON/OFF Pushbuttons (x2) - Allows the inverter or charger to be independently and quickly enabled or disabled. • Menu Pushbuttons (x5) - The menu pushbuttons allow the inverter or charger to be configured to your specific system preferences. These menus also allow simple access to menu items that can help with monitoring and troubleshooting your inverter/charger system. • Rotary Knob / SELECT button - The rotary encoder knob is similar to a dash radio knob and used to quickly scroll through and select various menu items and settings. Pushing this rotary knob allows you to “SELECT” a menu item or to “save” a setting once it is displayed on the LCD screen. ©2009 Magnum Energy Inc.

2.0 Installation 2.0 Installation Before installing the remote, read the entire installation section to determine how you are going to install your ME-RC. The more thorough you plan in the beginning, the better your inverter needs will be met. Info: Installations should be performed by qualified personnel, such as a licensed or certified electrician. It is the installer’s responsibility to determine which safety codes apply and to ensure that all applicable installation requirements are followed. Applicable installation codes vary depending on the specific location and application. Info: Review the “Important Product Safety Information” on the front inside cover page before any installation.

2.1 Installation Guidelines • Before connecting any wires, determine the remote cable route throughout the home or vehicle/boat both to and from the inverter. • Always check for existing electrical, plumbing or other areas of potential damage BEFORE drilling or cutting into walls to mount the remote. • Make sure all wires have a smooth bend radius and do not become kinked. • If installing this remote in an boat, RV or truck; ensure the conductors passing through walls, bulkheads or other structural members are protected to minimize insulation damage such as chafing, which can be caused by vibration or constant rubbing.

2.2 Tools Required Installing the remote control is a simple process and requires the following tools: • Phillips screwdriver • Level • Drill • Cut-out tool (knife/saw) • Pencil • Drill Bit (7/64”)

2.3 Installation Procedure 1. Select an appropriate location to install the remote control. Allow ample room to access the remote’s adjustment dial and to view the LEDs. Ensure the viewing angle of the display is appropriate. 2. Refer to figure 2-1 for hole and cutout dimensions. 3. Run the remote cable between the remote and the inverter/charger. This cable is a 4-wire, twisted-pair, telephony standard with RJ11 connectors on each end. A standard telephone cable may be substituted if the provided remote cable is not able to be used. 4. Connect the remote cable into the RJ11 “Remote” port (has blue label) on the inverter/charger (see figure 2-2). 5. Have the inverter connected to batteries, but ensure the inverter is off and that no AC power is connected to the inverter.


2.0 Installation

C U T O U T T H IS AREA

3 1 /4 "

2 7/8 "

5 1/4 "

(d ia g ra m n o t to sca le )

4 7/8 " Figure 2-1, Remote Cut-Out Dimensions Info: All power to operate the remote control is provided by the inverter/charger through the remote cable. 6. While monitoring the front of the remote, connect the other end of the cable into the RJ11 jack on the back-side of the remote (see figure 2-2). 7. Immediately upon connecting the remote cable, all the LED’s will come on as the unit goes through a self-test. After the initial self-test completes, text should appear with a system status message indicating the current state of the inverter/charger. If not, please refer to the troubleshooting section. 8. Secure the remote to the wall using the four 6 x 3/4” screws provided. 9. The remote is ready for set-up.

M agnum Inverter

RJ 11 connection

M E -R C R em ote Co ntr ol (ba ck v iew )

Rem ote cable REM O TE Port (blue label ) Figure 2-2, Remote Control Connections ©2009 Magnum Energy Inc.

3.0 Setup 3.0 Setup When the remote is connected to a Magnum inverter/charger, the settings in the remote control determine the inverter/charger operating parameters. The default settings in the remote control (see Table 3-4, Inverter/Charger Default Settings) are adequate for most installations, however you have the option to change some of the operating parameters if required. This section will show you how to navigate the remote, give you an understanding of the function of each adjustable setting and help you decide what setting should be used.

3.1 Navigating the Remote’s Menu The ME-RC has an internal structure that provides menu items and adjustable settings that provide the ability to configure your inverter/charger to your specific parameters. Info: See figure 4-1, Inverter/Charger Menu Map for a complete map of the inverter/charger menu items and adjustable settings. Familiarize yourself with the items on the front panel which are used to find, adjust and save the desired setting. They are: • LCD Display - The bottom line of the LCD display shows the menu items, adjustable settings or the meters display information. Info: The bottom line of the LCD display returns to the Home Screen to show DC voltage and current (see Figure 3-1) after 2 minutes - if no buttons have been pressed. Info: When the ”←” (left facing arrow) symbol is shown on the display, it indicates that the displayed setting has been selected and will be used. • Menu Pushbuttons (x5) - These five menus allow simple access to the menu items that can help with configuring, monitoring and troubleshooting your inverter/charger system. • Rotary SELECT Knob - This knob allows you to quickly scroll through and select various menu items and settings after pressing a menu pushbutton. This knob is also used to “save” a setting once it is displayed on the LCD screen and will refresh the LCD display by holding this knob down for 10 seconds.

Inverting DC: 12.6V

LCD Display

Menu Buttons

50A

Rotary SELECT Knob

Figure 3-1, Front Panel Set-up Features


3.0 Setup . Press the SETUP Menu button .

Inverting 01 Search Watts

Bottom line shows a menu item.

2. Turn the SELECT knob to the desired menu item.

Inverting 04 Battery Type

When the bottom line shows the desired menu item -

3. Press the SELECT knob .

Inverting BatType=Flooded

Bottom line shows current setting* (indicated by a ). *[if this setting is correct, press the SELECT knob to continue to the next menu item]. . Turn the SELECT knob to the desired setting.

Inverting BatType= AGM 1

When the bottom line shows the desired setting 5. Press the SELECT knob to “save” this desired setting.

Figure 3-2, SETUP Menu Navigation ©2009 Magnum Energy Inc.

3.0 Setup 3.2 Menu Pushbuttons and Menu Items The five menu pushbuttons (SHORE, AGS, METER, SETUP or TECH) allow the inverter/charger system to be configured to your specific preferences. These menus also allow you to access menu items that can help with monitoring and troubleshooting your system. Read this section to help understand the function of each Menu pushbutton and the configurable settings - to determine if they should be changed to optimize the operation of the inverter/charger. 3.2.1 SHORE Menu This menu pushbutton gives a quick means of changing your Shore Max setting to coordinate with the circuit breaker rating from the incoming AC source. • SHORE: Shore Max - This selection ensures the inverter AC loads receive the maximum current available from the utility or generator power. Whenever the utility or generator is connected to the inverter (thru AC HOT 1), the current used to power the AC loads and to charge the batteries is monitored. When the total current used to power the AC loads and charge the batteries begins to approach the Shore Max setting, the current that was used for charging the batteries will automatically be reduced. This ensures the AC loads have all the available current when needed. Default setting: Shore Max = 30A

Bottom line show s current “saved” setting Status… Shore Max = **A

SH OR E

press

If a different setting is required:

If this setting is correct , press another m enu button to access different m enu item s

Status ... Shore Max = 5A

.......

Status... Shore Max = 30A

rotate to desired selection :



press to save


Figure 3-3, SHORE: Shore Max Selections Where to set: Set the Shore Max setting to match the current rating of the utility power or generator’s circuit breaker. If using multiple AC sources (utility and generator) through an AC transfer switch, adjust this setting to the smaller AC breaker size. This setting is very dependent on the stability of the AC source. If using a generator, factors such as altitude and output voltage regulation may require a lower setting than the generator’s breaker size. For best performance, lower this setting to 1/3 its rated capacity and gradually increase while ensuring the voltage level stays above the SETUP: 06 VAC Dropout setting. CAUTION: The Shore Max setting does not limit the current to the inverter loads. If the current from the loads on the output of the inverter are greater than the circuit breaker rating on the incoming AC source, you may experience nuisance tripping on this breaker.


3.0 Setup 3.2.2 AGS Menu The AGS menu pushbutton allows the optional Auto Generator Start (AGS) controller (if installed and networked) to be configured to your specific system preferences and check status of the AGS. Info: Refer to the ME-AGS-N Owner’s Manual (part number: 640005) for detailed information on the Magnum Energy Auto Generator Start (ME-AGS-N) and this menu.

Status… 01 AGS Control SH OR E

AGS

METER

SETU P

TEC H

press

Figure 3-4, AGS Menu Display 3.2.3 METER Menu Pressing the METER menu pushbutton gives you access to different meters, which helps determine the status of the inverter/charger and battery system. METER: 01 INV/CHG Meter - This menu provides the DC voltage and • current while either inverting or charging. The DC: V (Volts) display provides the voltage from the batteries connected to the inverter. The DC: V accuracy is ±1.5% with a 0.1 VDC resolution. While inverting, the DC: A (Amps) displays a negative number to show the battery current used by the inverter. If you are charging, the DC A (amps) displays a positive number to show the amount of current delivered to the batteries. The accuracy of this display below 1 amp AC (~10 amps DC @ 12VDC) is not detected. When the current into or out of the batteries is greater than 1 amp AC, the display accuracy is ±20%.

METER

press

display show s m enu item : Status… 01 INV/CHG Meter

display show s D C m eter: press to select

Status… DC: **V

**A

Figure 3-5, METER: 01 INV/CHG Meter Display • METER: 02 BM: SOC thru 06 BM: TECH - These menus allow the optional ME-BMK (Magnum Energy’s Battery Monitor Kit) - if installed - to be configured to your specific system preferences and display the status of the battery system; refer to the ME-BMK Owner’s Manual (part number 640013) for detailed information on the Battery Monitor Kit and these menus.


3.0 Setup 3.2.4 SETUP Menu Pressing the SETUP menu pushbutton provides access to the menu items and settings that allow the inverter/charger to be configured. Read each menu item to determine if any setting requires adjustment to meet your requirements. • SETUP: 01 Search Watts - Allows you to turn off the Search Watts feature or adjust the power level to determine when the search watts feature becomes active. The power level range selection is 5W to 50W. If this feature is not needed, select Search=Off. When search is turned off, the inverter continuously provides full AC voltage to the loads. Default setting: Search= 5W. Info: When the Search Watts feature is active, “Searching” appears on the top line of the LCD display and the green ‘INV’ LED will slowly flash.

SETU P

rotate to Status… 01 Search Watts

press Status ... Search =

Off

Status... Search =

5W

press to select Status ... Search =

10W

.......

rotate to desired selection : Status ... Search =

30W

press to save Status ... Search =

50W

Figure 3-6, SETUP: 01 Search Watts Selections What is the “Search Watts” feature? This feature is used to help save battery power by reducing the inverter’s output to search pulses when there is no detectable load. If someone turns on a load greater than the wattage level setting while the inverter is “searching”, the inverter will start “inverting” to provide full voltage on its output. Should I use the “Search Watts” feature? If the inverter can spend a great deal of time “searching” (to reduce the power drain on your batteries) and you can tolerate small loads (less than 5 watts) from being on, then the search mode feature should be used. However, if you require some small load (i.e. digital clocks, satellite receivers, answering machines, etc.) to always be on, then this feature should be turned off (Search = Off). I want to use the Search Watts feature, how do I determine where to set it? The search watts setting should be adjusted to the same power level (or the next lower setting) of the smallest load that you want to run. If you don’t know the wattage of the smallest load you want to run, turn the load on and decrease the Search Watts setting until the load comes on and stays on. Example: You have reviewed all the loads you want to run and determined that the smallest load is a 30 watt light, then set the Search = 30W. Whenever you turn on any load (because all the loads are greater than 30 watts), the inverter will stop “searching” and start “inverting” to deliver power to the load. Note: Even though the search feature is on, some connected equipment may draw enough current even while in the “off” position to keep the inverter in the “inverting mode”.


3.0 Setup • SETUP: 02 LowBattCutOut - The Low Battery Cut-Out (LBCO) setting is used to set the DC voltage level that turns off the inverter to help protect the batteries from over-discharge damage. Selections are from 9.0 VDC to 12.2 VDC (12-volt inverter models), 18.0 VDC to 24.4 VDC (24-volt inverter models), or 36.0 to 48.8 (48-volt inverter models). If the battery voltage drops below the LBCO selected set-point continuously for more than 1 minute, the fault LED will come on, the inverter will turn off, and the display will show a ‘Low Battery’ status. If the battery voltage falls below 8.5 volts (12-volt models), 17.0 volts (24-volt models), or 34.0 (48-volt models); the fault LED and ‘Low Battery’ status will be immediate. Default settings: LBCO = 10.0 VDC (12-volt models), 20.0 VDC (24-volt models) or 40.0 VDC (48-volt models). Info: The inverter will automatically begin to start inverting when the DC voltage increases to ≥ 12.5 VDC (12-volt models), ≥ 25.0 VDC (24-volt models) or ≥ 50.0 VDC (48-volt models). If AC power is available and connected to the inverter’s input, the inverter will automatically clear the ‘Low Battery’ fault, pass the input AC power to the output and begin charging the batteries.

SETU P

press

rotate to Status… 02 LowBattCutOut

Status ... LBCO = 9.0VDC

Status... LBCO = 9. 5VDC

press to select Status ... LBCO = 10.0VDC

.......

rotate to desired selection : Status... LBCO = 12.0VDC

press to save Status... LBCO = 12.2VDC

Figure 3-7, SETUP: 02 LowBattCutOut Selections (12-volt shown) Where do I set the LBCO setting? If you want to cycle the batteries slightly - but don’t want to discharge them more than 20%*, then the LBCO setting should be set from 11.5 to 12.2 VDC (12-volt models), 23.0 to 24.4 VDC (24-volt models) or 46.0 to 48.8 (48-volt models). In some applications, such as installed in an off-grid home or doing a lot of dry-camping in your RV, you may want to cycle down to 50%* by setting the LBCO from 10.0 to 11.4 VDC (12-volt models), 20.0 to 22.8 VDC (24-volt models) or 40.0 to 45.6 VDC (48-volt models). In extreme circumstances, you have the ability to discharge the batteries to 80%* by setting the LBCO to 9.0 or 9.5 VDC (12-volt models), 18.0 or 19.0 VDC (24-volt models), or 36.0 or 38.0 VDC (48-volt models) before recharging. * These discharge percentage are rough estimates; for accurate battery monitoring, a battery monitor such as Magnum’s ME-BMK is required. Info: The higher the LBCO setting, the less the inverter will discharge the batteries; which should allow the batteries to have a longer life. The downside to a higher LBCO setting is that you need to charge more often to prevent the inverter from shutting down. Info: If there is an Auto Generator Start device installed, it should be set to start ≥1.0 volts higher than the LBCO setting – this is to prevent the inverter from shutting down before the generator comes on.


3.0 Setup • SETUP: 03 Batt AmpHrs - Used to select the approximate capacity of the battery bank connected to the inverter. This setting determines the time the battery charger is in the Absorb Charging stage (i.e. Absorption Time). See Table 3-1 to correlate the battery capacity to the Absorption Time; selections are in 10 AmpHrs increments from 200 to 2500 AmpHrs. Default setting: Batt AmpHrs= 400 Table 3-1, Battery AmpHrs to Absorb Charging Time Battery AmpHrs Selected

Absorb Charging Time

200 to 300

60 minutes

310 to 500

90 minutes

510 to 700

120 minutes

710 to 900

150 minutes

910 to 1100

180 minutes

1110 to 1300

210 minutes

1310 to 1500

240 minutes

1510 to 1700*

270 minutes

1710 to 1900*

300 minutes

1910 to 2100*

330 minutes

2110 to 2300*

360 minutes

2310 to 2500*

390 minutes

* these settings are active only on newer inverter revisions

SETU P

press

rotate to Status… 03 Batt AmpHrs

Status ... Batt AmpHr = 200

...

Status ... Batt AmpHr= 390

press to select Status... Batt AmpHr = 400


Status... Batt AmpHr = 410

...

press to save Status... Batt AmpHr = 2500

Figure 3-8, SETUP: 03 Batt Amphrs Selections Where do I set the Battery Amp-Hour setting? Select the setting based on the 20-hour Amp-Hour (AH) capacity of your battery bank. How do I determine my Battery Amp-Hour capacity? The inverter requires deep cycle batteries, which are specifically made for continuous use. Deep cycle batteries are rated either by a) amp-hours or b) reserve capacity in minutes. a) Amp-hour (AH) capacity is a measurement of how many amps a battery can deliver for a specified length of time (usually 20 hours) until the voltage achieves 1.75 VDC / cell at 80° F. b) Reserve Capacity (RC) is a measure of how many minutes a battery can deliver a certain amount of current (usually 25A) and maintain a voltage above 1.75 VDC/cell at 80° F. Info: If using the Reserve Capacity (25A), the 20-hour AH capacity can be estimated by multiplying “minutes reserve capacity” by 50%. 10


3.0 Setup Table 3-2 below provides an estimated 20-hour Amp-Hour capacity based on the group/code size, physical size and voltage of the battery. If you are not sure of your battery’s 20-hour AH rating, consult your battery manufacturer/ dealer or use the table below to obtain an estimate. Table 3-2, Battery Size to Battery Amp-Hours (estimated) Group / Code Size

Physical Size (L” x W” X H”)

Battery Battery AHrs Voltage (20-hour rate)

GC-2 (Golf Cart)

10 3/8 x 7 13/16 x 10 5/8

6V

220 AmpHrs

L16

11 11/16 x 7 x 16 11/16

6V

375 AmpHrs

Group 22

9 1/2 x 6 7/8 x 8 5/16

12V

55 AmpHrs

Group 24

10 1/4 x 6 13/16 x 8 7/8

12V

70 AmpHrs

Group 27

12 1/16 x 6 13/16 x 8 7/8

12V

95 AmpHrs

Group 31

13 x 6 13/18 x 9 7/16

12V

110 AmpHrs

4D

20 3/4 x 8 3/4 x 9 7/8

12V

200 AmpHrs

8D

20 3/4 x 11 1/8 x 9 7/8

12V

250 AmpHrs

Once you’ve determined the Amp-hour capacity of each battery, review how your batteries are connected (parallel or series) to determine the total amphour capacity of the battery bank: Parallel connection – batteries connected in parallel (positive to positive, negative to negative) increase the amp-hour capacity of the battery bank, but the voltage remains the same. For example: You have a 12-volt battery bank with three 12-volt batteries that are rated at 125 Amp-Hours (AH) each. Each of the positive terminals are connected together and each of the negative terminals are connected together, which means they are connected in parallel. The amp-hours of each battery connected in parallel are added together (125 AH + 125 AH + 125 AH = 375 AH), but the voltage of the battery bank stays the same (12 VDC). Series connection - batteries connected in series (positive to negative) increase the voltage of the battery bank, but the amp-hour rate remains the same. For example: You have a 12-volt battery bank with two 6-volt batteries that are rated at 220 amp-hours. The positive terminal of the first battery is connected to the negative terminal of the second battery, which means these batteries are connected in series. Since the two 6-volt batteries are connected in series, the voltage of the batteries are added together to produce 12-volts (6 VDC + 6 VDC = 12 VDC), but the amp-hour capacity of the battery bank does not change (220 AH). In battery banks where you have batteries connected in series and in parallel –the rules are the same. The batteries connected in series are referred to as a “series string” and the amp-hour capacity doesn’t change. Each “series string” is connected together in parallel to increase the amp-hour capacity. Add the amp-hour capacity of each “series string” connected in parallel to determine the total amp-hour capacity of the battery bank.

©2009 Magnum Energy Inc. 11

3.0 Setup • SETUP: 04 Battery Type - Used to select the battery type, which determines the battery charge profile and ensures the batteries are receiving the proper charge voltage. The fixed voltage selections are GEL (for Gel batteries), Flooded (for liquid lead acid batteries), AGM 1 (for Lifeline AGM batteries) and AGM 2 (for East Penn/Deka/Discover/Trojan AGM batteries); The ‘Custom’ selection allows the Float and Absorb charge voltage settings to be individually adjusted. See Table 3-3 to determine the specific charge voltage based on the Battery Type selected. Default setting: BattType = Flooded The voltage settings shown in Table 3-3 are based on the Battery Temperature Sensor (BTS) being disconnected or at a temperature of 77° F (25° C). If the BTS is connected, the actual charge voltage will increase if the temperature around the BTS is below 77° F (25° C) and decrease if higher than 77° F (25° C). This ensures the batteries receive the correct charge voltage even if they become cold or hot. Table 3-3, Battery Type to Charge Voltages Battery Type GEL

Flooded

AGM 12

AGM 23

Custom4

Inverter Voltage 12 24 48 12 24 48 12 24 48 12 24 48 12 24 48

VDC VDC VDC VDC VDC VDC VDC VDC VDC VDC VDC VDC VDC VDC VDC

Absorption Voltage

Float Voltage

Equalization Voltage

14.1 VDC 13.6 VDC 28.2 VDC 27.2 VDC 56.4 VDC 54.4 VDC 14.6 VDC 13.4 VDC 29.2 VDC 26.8 VDC 58.4 VDC 53.6 VDC 14.3 VDC 13.1 VDC 28.6 VDC 26.2 VDC 57.2 VDC 52.4 VDC 14.5 VDC 13.5 VDC 29.0 VDC 27.0 VDC 58.0 VDC 54.0 VDC 12.0-16.0 VDC 12.0-16.0 VDC 24.0-32.0 VDC 24.0-32.0 VDC 48.0-64.0 VDC 48.0-64.0 VDC

14.1 VDC1 28.2 VDC1 56.4 VDC1 15.5 VDC 31.0 VDC 62.0 VDC 15.5 VDC 31.0 VDC 62.0 VDC 14.5 VDC1 29.0 VDC1 58.0 VDC1 15.5 VDC 31.0 VDC 62.0 VDC

Note 1: voltage same as absorption voltage - to prevent equalization. Note 2: specifications for Concord (Lifeline Series) AGM batteries. Note 3: specifications for East Penn, Deka, Discover and Trojan AGM batteries. Note 4: requires inverter with enabled software to operate.

SETU P

press

rotate to Status… 04 Battery Type

Status... BatType= GEL

Status... BatType=Flooded

press to select Status... BatType= AGM 1


Status... BatType= AGM 2

press to save

Status... BatType= Custom

Figure 3-9, SETUP: 04 Battery Type Selections 12


3.0 Setup • SETUP: 05 Charge Rate - Used to set the maximum charge rate allowed to charge the batteries during bulk, absorption, float and equalize charging. Selections are ‘Max Charge = 0%’ up to ‘Max Charge = 100%. The Max Charge = 0% setting is available to help minimize charging while continuing to allow pass-thru power. The rest of the selections are provided to limit the charge rate to the battery bank, which helps prevent battery overheating caused by charging at too high a charge rate. The Max Charge selections are provided as a percentage of the inverter/ charger’s maximum charging capability. Refer to label on the side of the inverter or the operator’s manual for the inverter/charger to determine its maximum charge rate. Once you find this maximum charge rate, determine the percentage needed to limit the charge rate to your battery-bank. For example, if the maximum charge rate of your inverter/charger is 100 amps and you need to limit the charge rate to 50 amps, choose the Max Charge = 50% selection (50 amps = 50% of 100 amps). Default setting: Max Charge = 80%

SETU P

press

rotate to Status… 05 Charge Rate

Status ... Max Charge = 0%

Status ... Max Charge= 10%

.......

press to select


Status... Max Charge= 80%

Status... Max Charge= 90%

press to save Status... Max Charge= 100%

Figure 3-10, SETUP: 05 Charge Rate Selections Info: If the Max Charge rate is set to 0%, the topology of the Magnum Inverter - when connected to an AC source - will over-ride the 0% setting and start charging if the battery voltage is 25.6 / 24-volt models or >51.2 / 48-volt models), the charger will skip the Bulk and Absorb charging stages and go directly to Float Charging. PWR FAULT CHG INV

Bulk Charging Settings/Info...

Bulk Charging appears on LCD; PWR (green) is on solid and CHG (green) LED is typically on solid, but may blink slowly; FAULT (red) LED is off; INV (green) LED could be on or off.

Figure 5-6, Bulk Charging Mode • Bulk Charging – The battery charger is delivering maximum current (determined by the SETUP: 05 Charge Rate setting) to the batteries. The charger will remain in bulk charge until the absorb voltage (determined by the SETUP: 04 Battery Type setting) is achieved.

PWR FAULT CHG INV

Absorb Charging Settings/Info...

Absorb Charging appears on LCD; PWR (green) is on solid and CHG (green) LED is typically on solid, but may blink slowly; FAULT (red) LED is off and INV (green) LED could be on or off.

Figure 5-7, Absorb Charging Mode • Absorb Charging - The absorb charge state is the constant voltage stage and begins when the absorb voltage is reached (determined by the SETUP: 04 Battery Type setting) while bulk charging. During this stage, the DC charging current decreases in order to maintain the absorb voltage setting. This charge stage continues until the Absorb Charging time (determined by the SETUP: 03 Battery AmpHrs setting) is finished. 24


5.0 Operation PWR FAULT CHG INV

Float Charging Settings/Info...

Float Charging appears on LCD; PWR (green) LED is on solid and CHG (green) LED is typically on solid, but may blink slowly; FAULT (red) LED is off and INV (green) LED could be on or off.

Figure 5-8, Float Charging Mode • Float Charging – At the end of the Absorb Charging time, the charger reduces the charge voltage and tries to maintain the batteries at the float charge voltage setting; which is determined by the SETUP: 04 Battery Type setting as shown in Table 3-3, Battery Type to Battery Charge Voltages. Info: If the battery voltage falls ≤12.1 VDC (12-volt models), ≤24.2 VDC (24-volt models) or ≤48.4 VDC (48-volt models); the unit will begin bulk charging. PWR FAULT CHG INV

Full Charge Settings /Info...

Full Charge appears on LCD; PWR (green) LED is on solid and CHG (green) LED blinks slowly; FAULT (red) LED is off and INV (green) LED could be on or off.

Figure 5-9, Full Charge Mode • Full Charge – This status indicates that you have entered the Battery Saver™ mode. This mode maintains the batteries without overcharging, thus preventing excessive loss of water in flooded batteries or drying out of GEL/ AGM batteries. After 4 hours “Float Charging”, the charger will turn off and “Full Charge” is displayed (charger is now in Battery Saver™ mode). If the battery voltage drops to ≤12.6 (12-volt models), ≤25.2 (24-volt models) or ≤50.4 (48-volt models); the charger will automatically initiate another 4 hours “Float Charging”. This cycle helps to ensure the batteries are monitored and maintained; and continues as long as AC power is continuously connected to the AC input. PWR FAULT CHG INV

Charger Standby Settings /Info...

Charger Standby appears on LCD; PWR (green) LED is on solid and CHG (green) LED slowly blinks; FAULT (red) LED is off and INV (green) LED could be on or off.

Figure 5-10, Charger Standby Mode • Charger Standby - This means the charger has been disabled to prevent any charging, but the AC power (from shore/utility or generator) to the AC input is still available on the AC output. This display is shown when the ON/OFF CHARGER pushbutton is pressed while the AC power is passing thru the inverter/charger. Info: To enable charging again, press the ON/OFF CHARGER pushbutton. When the charger is again enabled, the charger will continue in the charge mode it left and the CHG (green) LED will come on solid.


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Equalizing Settings/Info...

Equalizing appears on LCD; PWR (green) and CHG (green) LED’s are on solid; FAULT (red) LED is off and INV (green) LED could be on or off.

Figure 5-11, Equalizing Mode Equalizing - The battery charger is delivering the equalize voltage to the batteries; see Table 3-3, Battery Type to Battery Charge Voltages to determine the equalize voltage for your battery type. Equalize charging can be enabled by the ON/OFF CHARGER pushbutton - if the SETUP: 04 Battery Type selection allows. Equalization charging can only be enabled while the charger is in float charge or in Battery Saver mode. To turn on equalize charging, ensure the LCD display reads “Float Charging” or “Full Charge”, then press and hold the ON/OFF CHARGER pushbutton down (about 5 seconds) until the LCD screen displays “Equalizing”. The equalize charge will continue for 4 hours and then automatically stop and return to “Float Charging”. The equalize charge can be manually stopped by pressing and holding the ON/OFF CHARGER pushbutton down (about 5 seconds) until the LCD screen displays “Float Charging”. During equalize charge stage the batteries will begin gassing and bubbling vigorously which consumes water; ensure each cell has adequate distilled water levels prior to equalizing and add water as needed after equalizing. How often should I equalize? Some experts recommend that heavily used batteries should be equalized periodically, ranging anywhere from once a month to once or twice per year. Other experts only recommend equalizing when the cells have a low specific gravity or when the difference between any individual cell has a specific gravity reading greater than .015 after being fully charged. How long should I equalize? While the batteries are gassing, monitor the specific gravity readings every hour; when the specific gravity readings no longer increase, the equalization charge is complete and should be stopped. WARNING: Equalizing produces hydrogen and oxygen gas. Ensure the battery compartment has adequate ventilation in order to dissipate this gas to avoid explosions. CAUTION: Ensure you batteries can be equalized - only equalize your batteries if permitted by your battery manufacturer or dealer. Performing an equalize charge on batteries other than liquid lead acid or certain AGM types could permanently damage them. Refer to your battery manufacturer/dealer for instructions on how to properly equalize your batteries. CAUTION: Ensure the DC loads will not be damaged by the higher voltage applied to the batteries during the equalize charge. If in doubt, disconnect the DC loads to prevent damage. Info: Equalization charging is not available if GEL or AGM 2 is selected under the SETUP: 04 Battery Type menu.

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5.0 Operation 5.3.3 Fault Mode Messages The fault LED comes on and a fault status is displayed when an abnormal condition is detected. View the LCD display and the information in this section to determine and correct the issue. Info: Many of the faults will automatically restart when the fault is cleared. Some faults will require a manual restart; this requires the ON/ OFF INVERTER pushbutton on the remote to be pressed and released. Finally, if the fault is unable to clear, an inverter reset may be required - see section 6.2 to perform an inverter reset. 5.3.3.1 System Fault messages - These fault messages are usually caused by some external issue that directly affects the inverter/charger system. PWR FAULT CHG INV

Low Battery Settings/Info...

Low Battery appears on the LCD and the FAULT (red) LED is on. The PWR (green), CHG (green) and INV (green) LED’s are off.

Figure 5-12, Low Battery Fault • Low Battery – The inverter turned off to help prevent the batteries from being over-discharged. This message is displayed and the FAULT (red) LED illuminates when the battery voltage drops below the SETUP: 02 LowBattCutOut (LBCO) setting for more than 1 minute. The inverter will automatically restart and resume operation when the battery voltage rises to ≥12.5 VDC (12-volt models), ≥25.0 VDC (24-volt models), or ≥50.0 VDC (48-volt models). Remedy: This fault will also automatically restart if AC power (such as utility/shore power or a generator) is connected to the inverter/ charger’s input and battery charging begins. PWR FAULT CHG INV

High Battery Settings/Info...

High Battery appears on the LCD and the FAULT (red) LED is on. The PWR (green), CHG (green) and INV (green) LED’s are off.

Figure 5-13, High Battery Fault • High Battery – The inverter has turned off because the battery voltage is at a very high level. This fault message is displayed and the FAULT (red) LED will be on when the battery voltage is above the High Battery Cut-Out (HBCO) value. This fault will automatically restart and resume operation when the battery voltage drops 0.3 VDC (12-volt models), 0.6 VDC (24-volt models), or 1.2 VDC (48-volt models) below the HBCO value. Info: The HBCO value is dependent on your inverter revision and model. Normally, the HBCO value for the ME/MM/RD Series inverters is 16 VDC (12-volt models) or 32 VDC (24-volt models); and the HBCO value for the MS/MMS Series inverters is 17 VDC (12-volt models), 34 VDC (24-volt models), or 68 VDC (48-volt models). Remedy: This fault usually only occurs when an external DC charging source is charging the inverter’s battery bank. Turn off any other additional charging source to allow the DC voltage level to drop. ©2009 Magnum Energy Inc.

27


Overtemp Settings/Info...

Overtemp appears on the LCD and the FAULT (red) LED is on. The PWR (green), CHG (green) and INV (green) LED’s are off.

Figure 5-14, Overtemp Fault • Overtemp – This fault message indicates the inverter/charger has shut down because the internal power components (FET’s and/or Transformer) have exceeded their safe temperature operating range. When the unit has cooled down, it will automatically restart and continue operation. Remedy: If the fault occurs while inverting, reduce the load on the inverter; if it occurs while charging, turn down the charge rate. If this fault happens often, ensure the inverter is not in a hot area, has proper ventilation and the cooling fans inside the inverter are working.

PWR FAULT CHG INV

AC Overload Settings/Info...

AC Overload appears on the LCD and the FAULT (red) LED is on. The PWR (green), CHG (green) and INV (green) LED’s are off.

Figure 5-15, AC Overload Fault • AC Overload - This fault message displays when the AC load on the inverter/ charger’s output has exceeded the inverters AC current protection limits. If the overload condition lasts for less than 10 seconds, the unit will automatically restart and resume operation. However, if the overload occurs more than 10 seconds, the unit will shut down and will require a manual restart. Remedy: This fault usually occurs because the connected AC loads are larger than inverter’s output capacity, there is a wiring short on the output or the output wires are incorrectly wired. Once the AC loads are reduced or the output wiring is corrected; the inverter can be restarted after a manual restart has been accomplished. PWR FAULT CHG INV

High Volts AC Settings/Info...

High Volts AC appears on the LCD and the FAULT (red) LED is on. The PWR (green), CHG (green) and INV (green) LED’s are off.

Figure 5-16, High Volts AC Fault • AC High Volts AC - This fault causes the charger to be disabled because a very high AC voltage (>150 VAC) has been detected on the AC input. Remedy: Remove all AC power from the inverter’s AC input for at least 15 minutes to automatically restart this fault; ensure only 120VAC power is connected to each of the inverter’s AC inputs.

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Dead Batt Charge Settings/Info...

Dead Battery Charge appears on the LCD and the FAULT (red) LED is on. The PWR (green), CHG (green) and INV (green) LED’s are off.

Figure 5-17, Dead Battery Charge Fault • Dead Battery Charge – This fault has detected a very discharged battery bank or a battery bank that is disconnected from the inverter. The unit is attempting to enter the charge mode, but has detected less than 9 volts (12-volt models), 18 volts (for 24-volt models) or 36 volts (for 48-volt models) on the battery bank. This fault will continue until current is able to flow into the battery from the battery charger. Once this happens, the fault will automatically restart. Remedy: Check the DC voltage on the inverter’s DC terminals and ensure it is the same as the battery bank, these two voltages should be very close (